Skyjack SJ643 TH Operating Manual Download Page 11

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SJ643 TH & SJ843 TH

216201ADA

Symbols & Nomenclature

Section 1 – About Your Telehandler

Symbol

Description

Symbol

Description

Diesel Fuel
Fuel Tank

Engine Oil Level

Engine Air Intake

Hydraulic Oil

Engine Coolant

Hydraulic Oil Level

Engine Coolant Level

Positive Air Shutoff (Engine high idle)

Drain Water/Fuel Separator

Transmission Oil Level

Engine Oil

1.2 Symbols & Nomenclature

1.3 Forklift Hand Signals

1. Stop

3. Retract boom

2. Emergency
Stop

7. Hoist load

8. Lower load

9. Tilt forks/attachment
up

10. Tilt forks/
attachment
down

5. Raise boom/mast

6. Lower boom/mast

11. Travel
backwards

12. Travel
forwards

4. Extend boom

13. Swing
attachment
left

14. Swing
attachment
right

15. Fork Spread -
Closed

16. Fork Spread -
Open

Summary of Contents for SJ643 TH

Page 1: ...OPERATING MANUAL SJ643 TH SJ843 TH TELEHANDLER 216201ADA July 2018 ANSI CSA...

Page 2: ...110 609 Above This manual is based on Serial Number Please refer to the website www skyjack com for Contact Information other Serial Numbers most recent Technical Manuals and USB software Original ins...

Page 3: ...if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to al...

Page 4: ...216201ADA SJ643 TH SJ843 TH 4 Notes...

Page 5: ...sibility for Maintenance 13 1 6 1 Maintenance and Inspection Schedule 13 1 6 2 Owner s Inspections 13 Section 2 Operator Safety 15 2 1 Electrocution Hazard 15 2 2 Safety Precautions 16 2 3 Cab Access...

Page 6: ...rks 34 3 6 4 Jib Boom 34 3 6 5 Loader Bucket 35 3 6 6 Truss Boom 35 3 6 7 Fork Positioner 36 3 6 8 Personnel Work Platform 36 Section 4 Pre operation 37 4 1 Operator s Responsibility 37 4 2 Visual Dai...

Page 7: ...rating the Boom 58 5 4 1 Raising or Lowering Boom 58 5 4 2 Extending or Retracting Boom 58 5 5 Leveling the Telehandler 58 5 6 Tilting the Attachment 58 5 7 Handling Loads 58 5 8 Handling Loads at Gro...

Page 8: ...3 Installing Personnel Work Platform Using Forks 74 5 16 4 Platform Operation 75 Section 6 Additional Procedures 77 6 1 Refueling Procedure 77 6 1 1 Diesel Fuel 77 6 2 Lifting Skyjack SJ643 TH SJ843...

Page 9: ...d all other warnings in this manual and on the telehandler Compare the labels on the telehandler with the labels found within this manual If any labels are damaged or missing replace them immediately...

Page 10: ...t identified with CSA meets the CSA B335 15 standard 2 CSA Canada Operators are required to conform to national territorial provincial and local health and safety regulations applicable to the operati...

Page 11: ...ositive Air Shutoff Engine high idle Drain Water Fuel Separator Transmission Oil Level Engine Oil 1 2 Symbols Nomenclature 1 3 Forklift Hand Signals 1 Stop 3 Retract boom 2 Emergency Stop 7 Hoist load...

Page 12: ...mbly is welded to the end of last section in the boom assembly and includes a lifting hook for slinging loads The telehandler is equipped with a carriage tilt cylinder which is mounted to the inside o...

Page 13: ...ecklist see Section 4 4 even if the operator is not directly responsible for the maintenance of this telehandler 1 6 1 Maintenance and Inspection Schedule Refer to Service manual for quarterly or 250...

Page 14: ...216201ADA SJ643 TH SJ843 TH 14 Notes...

Page 15: ...Approach Distance MSAD of 10 ft from sources of power If the work requieres to be closer than 10 ft stop and consult a qualified person with respect to electrical transmission and distribution to hav...

Page 16: ...T wear loose clothing dangling neckties scarves rings wristwatches or other jewelry while operating this telehandler DO NOT use this telehandler under influence of alcohol or drugs or if operator s pe...

Page 17: ...BE AWARE of blind spots when operating the telehandler ALWAYS keep head arms hands legs and all other body parts inside the operator s cab AVOID jerks and sudden stops AVOID entanglement with ropes c...

Page 18: ...between obstacles ALWAYS wear your seat belt when operating this vehicle DRIVE DOWNHILL UNLOADED Without a load the back end is the heaviest part of the telehandler Driving downhill decreases potentia...

Page 19: ...n structure ROPS Do not make any modification to this structure If damaged the cab cannot be repaired It must be replaced STUNT driving and horseplay are prohibited ALWAYS USE FRONT steering when trav...

Page 20: ...ed or locked out for non use or repair bears an unapproved attachment Failure to avoid these hazards could result in death or serious injury 2 4 Jobsite Inspection Be sure to follow all local provinci...

Page 21: ...telehandler without proper authorization and training Failure to avoid this hazard could result in death or serious injury WARNING It is the responsibility of the operator to read completely understan...

Page 22: ...behind seat Section 3 2 Operator s Cab Section 3 4 3 Frame Level Cylitnder Section 4 2 4 Wheel Tire Assembly Drive Axle Section 4 2 6 Mirrors Section 4 2 5 Boom Lift Cylinders Section 4 2 4 Boom Exten...

Page 23: ...3 Cab Heater and Air Conditioner Controls If Equipped A switch and two knobs to adjust the temperature inside the cab 4 Rear View Mirror Allows the operator to check the surrounding area behind teleh...

Page 24: ...k backward Lower the boom by moving the joystick forward Extend the boom by moving the joystick to the right Retract the boom by moving the joystick to the left Tilt attachment forward by pressing and...

Page 25: ...joystick backward Lower the boom by moving the joystick forward Extend the boom by moving the joystick to the right Retract the boom by moving the joystick to the left Tilt attachment forward by hold...

Page 26: ...Display Module Allows the operator to select the required engine data such as engine RPM engine temperature voltage and visualize it in the following formats Analogue display Digital data Graphics Mul...

Page 27: ...d key returns to ON position 13 Horn Button When depressed the horn button activates an audible warning 14 12 Volt Power Port A convenient 12 Volt power port is located on the dashboard 15 Hourmeter T...

Page 28: ...pped This switch activates the front headlights and rear tail lights 22 Work Lights Switch If Equipped This switch activates the front and rear work lights located on top of operator s cab 23 Boom Lig...

Page 29: ...door is available as an option Included in this option are the windshield wiper s interior light and air heater defroster Air conditioner is also available as an option for fully enclosed cab 3 4 4 Op...

Page 30: ...terlock Light When activated the Frame Level and Boom Interlock Light 1 illuminates on the dash in the operator s cab see Section 3 3 4 3 4 6 Frame Level Allows the operator to laterally level the tel...

Page 31: ...The flashing beacon is located on top of the operator s cab This light is operational when key is in on position Figure 07 Flashing Beacon 3 5 4 Road Lights Boom Lights Work Lights If Equipped The boo...

Page 32: ...ndler A green status symbol 3 indicates the sensor and camera are connected and no objects are detected When in reverse and objects are detected the monitor beeps the status symbol turns red and range...

Page 33: ...function switch down 4 Handle load the same as regular fork carriage attachment refer to Section 5 8 and Section 5 9 3 6 2 Swing Carriage Figure 11 Swing Carriage Swing carriage allows forks to swing...

Page 34: ...d 2 Handle load the same as regular fork attachment ensuring all forks are in contact with the load at all times refer to Section 5 8 and Section 5 9 3 6 4 Jib Boom Figure 13 Jib Boom A jib boom is an...

Page 35: ...y into pile to load bucket 3 Tilt bucket backwards enough to retain the load and back away from pile 4 Drive to the unloading point and keep bucket approximately 4 ft above the ground 5 Tilt bucket fo...

Page 36: ...further apart hold left auxiliary function button down To bring forks closer together hold right auxiliary function button down 2 To operate using the Premium Multi functional Joystick if equipped To...

Page 37: ...ce IMPORTANT The operator must understand and follow the step by step instructions to test all telehandler functions The operator should make a copy of the Operator s Checklist see Section 4 4 and fil...

Page 38: ...al Maintaining the electrical components is essential to good performance and service life of the telehandler Ensure proper operation of all gauges Inspect the following areas for chafed corroded and...

Page 39: ...re may cause death or serious injury 5 Foam filled Tires Tire condition can vary significantly depending on telehandler use job site environment and preventative maintenance measures Inspect tires per...

Page 40: ...ng If contact occurs immediately flush with cold water and seek medical attention 1 Check battery case for damage 2 Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or w...

Page 41: ...s will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Perform a visual inspection around the following areas hoses and fittings fuel pump fuel filter fuel ta...

Page 42: ...e chunks of material missing Refer to service manual for proper replacement procedure 4 Hydraulic Oil Pump Ensure there are no loose or missing parts and there is no visible damage Ensure all bolts ar...

Page 43: ...tor Ensure all bolts are tight and there is no visible damage and indicator swings freely 4 2 10 Lifting Attachment 5 Ensure attachment is properly positioned and secured Refer to Section 5 13 Ensure...

Page 44: ...sign of visible damage Ensure seat belt is working properly with no sign of visible damage 3 Pedals Ensure brake and accelerator pedals are secure no loose or missing parts no sign of visible damage a...

Page 45: ...operator s cab controls 1 refer to Section 3 3 1 are secured with no sign of visible damage Ensure multi function joystick 2 refer to Section 3 3 2 or Section 3 3 3 is secured movements are not obstru...

Page 46: ...eration WARNING Entering and exiting the telehandler must only be done using the three points of contact method 1 Enter cab and close door if equipped WARNING The seat belt must be worn at all times 2...

Page 47: ...dal Result Rear brake lights should turn on 4 Select boom lights switch 2 if equipped to on position Result Boom lights should turn on 5 Select the front work lights switch 3 if equipped to on positio...

Page 48: ...t Attachment Functions Standard Multi functional Joystick 1 Tilt attachment forward by pressing and holding the carriage tilt enable button 2 while moving the joystick forward Result Attachment should...

Page 49: ...me level indicator should be at 0 4 3 7 Test Boom Interlock 1 Ensure park brake is engaged transmission shifter in neutral boom fully retracted and below 30 2 Frame level left and stop when the frame...

Page 50: ...3 and ensure path of intended motion is clear 3 Release parking brake Result Parking brake indicator light should turn off 4 Move transmission lever to REV reverse position and release the service bra...

Page 51: ...personnel or obstructions 3 Depress service brake move parking brake switch 1 to off position Result Parking brake indicator light should turn off 4 Move transmission lever to FWD 1st gear for powersh...

Page 52: ...o the left or right and drive forward Result Telehandler should move in the chosen direction producing a turning circle with front wheels pointing in the opposite direction to the rear wheels 6 Steer...

Page 53: ...engine is running and key is in on position 2 Ensure parking brake is engaged and transmission is in reverse 3 Depress and hold service brake pedal Release parking brake Result Range indicator lights...

Page 54: ...d 1235AB N A P F R Visual and Daily Maintenance Inspections Labels Electrical Hydraulic Cylinders Mirrors Frame Wheel Tire Assembly Air filled Tires Foam filled Tires Drive Axles Steer Cylinder Batter...

Page 55: ...on 2 4 4 If as a result of the risk assessment the need for rescue planning is identified a system of communication shall be established between people working on the platform and nominated support pe...

Page 56: ...ansmission control lever to the desired direction of travel 2 Release parking brake 3 Select first gear If equipped 4 Slowly release service brake pedal 5 Depress accelerator pedal slowly to increase...

Page 57: ...radius available WARNING Do not use four wheel steering mode when driving on public roads and highways Do not travel at high speeds 3rd gear for powershift transmission when using four wheel steering...

Page 58: ...ult Attachment should tilt backward Premium Multi functional Joystick If Equipped 1 Tilt attachment forward by pressing and holding the attachment tilt switch up Result Attachment should tilt forward...

Page 59: ...nd the lift 4 Approach load slowly with forks straight ahead and perpendicular to the load 5 Insert forks under the load making sure not to extend forks past the load so that any loads or equipment be...

Page 60: ...er during operations involving heavy loads Use a spotter when possible to assist in handling the load refer to Section 1 3 5 9 1 Picking up a Load 1 Move transmission lever to neutral and apply parkin...

Page 61: ...display warning flags during the day and flares or flashing lights at night 1 Position telehandler on a firm and level surface WARNING Always engage parking brake before leaving the cab 2 Bring teleha...

Page 62: ...nation Settings 1 Pressing button 5 calls up the Contrast and Illumination menu when the menu symbols are not displayed 2 Adjust illumination using button 1 for dimming or button 2 for brightening the...

Page 63: ...s through the top right display etc 7 Quit the display by pressing button 5 5 11 5 Graphic Display The graphic display shows data trends in a large window and functions like an analog data recorder 1...

Page 64: ...the DEUTZ Display This includes setting the units metric or US customary measuring range settings or engine service intervals 4 The configuration menu can be called up by pressing and holding down but...

Page 65: ...SJ643 TH SJ843 TH 216201ADA 65 Notes...

Page 66: ...ion between capacity zones the smaller of the two capacity values must be used NOTE The weight of the load must be equal to or less than the number in the capacity zone WARNING When handling loads ens...

Page 67: ...andard Taper 2 X 5 X 60 Standard Taper 1 75 x 7 x 48 Full Taper 1 75 x 7 x 60 Full Taper Rated capacity at 24 load center FORWARD REACH FT LIFT HEIGHT FT 5 45 40 35 0 30 25 20 15 10 5 0 30 25 20 15 10...

Page 68: ...r bar can be raised and tilted backwards to engage the attachment and lift it clear of the ground 5 Engage the attachment as described in step 4 aligning the holes in the attachment for the installati...

Page 69: ...r 4 Grasping the fork near its eye push the fork along the bar until it is in the desired position CAUTION Be careful not to pinch fingers between the fork and any portion of the attachment 5 13 4 Cha...

Page 70: ...ility for damages resulting from the use of third party attachments on any of its THS RTFLs It is permissible to install and utilize third party attachments provided they do not elevate personnel and...

Page 71: ...ctions in compliance with ANSI ITSDF B56 6 CSA B335 are permissible WARNING Never use a platform that has unapproved modifications or is damaged Failure to identify and avoid these hazards could resul...

Page 72: ...nnection 6 Secure the carriage hoses between the carriage and the platform as shown in figure 46 Figure 46 Hydraulic Hoses 7 Secure the locking device to the Personnel Work Platform as shown in figure...

Page 73: ...vice on both swing cylinders as shown in figure 48 Secure them with the quick release pins 2 5 After the locking device is installed disconnect the auxiliary hydraulic hoses and cover them with the ex...

Page 74: ...es WARNING End fork loops are to be used only for positioning the platform Never use fork loops to secure or elevate personnel or platform 3 Install the two steel retaining pins behind the heel of eac...

Page 75: ...rm All personal fall protection equipment must be attached only to approved anchorage points on the platform Only one lanyard may be attached to any anchorage point WARNING Never exceed rated lift cap...

Page 76: ...216201ADA SJ643 TH SJ843 TH 76 Notes...

Page 77: ...dler only in a well ventilated area away from open flame and other sources of ignition authorized by your employer and supervisor To minimize possible static electricity fires ensure filler nozzle tou...

Page 78: ...ock the rear axle by placing wood between the frame and the axle WARNING Use rigging with load capacity sufficient to withstand telehandler weight Refer to the serial plate of the telehandler for spec...

Page 79: ...ORTANT All turbo engine air cleaner and exhaust must be sealed during transport 1 Ensure telehandler is level prior to loading 2 Fully lower and retract boom 3 Ensure ramps are correctly positioned 4...

Page 80: ...are fully accessible 2 Carefully fasten tow chains to tie down points on either front or rear of telehandler frame 3 Remove chocks from wheels 4 Enter cab and fasten seat belt 5 Ensure transmission g...

Page 81: ...OM Never attempt to operate the boom or lift any load while telehandler is being utilized as a tow vehicle 6 5 1 Towing Pin The towing pin 1 utilizes the telehandler as a towing vehicle and is located...

Page 82: ...216201ADA SJ643 TH SJ843 TH 82 Notes...

Page 83: ...SJ643 TH SJ843 TH 216201ADA 83 Section 7 Specifications...

Page 84: ...ng Brake Three Speed Transmission Three Mode Steering Optional Equipment 1 75 Cu Yd Bucket Loader Attachment 12 ft Truss Boom 2 ft Jib Boom 48 60 72 Side Tilt Fork Carriages 72 Swing Carriage Back up...

Page 85: ...mph 25 km h CVT Range 0 mph 0 km h 15 mph 24 km h Electrical Negative ground 12 Volts Alternator 95 Amps Battery 90 Amps Backup Alarm 107 dBm Dimensions Wheelbase 128 in 325 12 cm Overall width 102 i...

Page 86: ...A BLACKSTONE FOAM 13 00 X 24 16 1458AA 7 3 Tire Wheel Specifications Table WARNING Do not use tires other than those specified for this machine Do not mix different types of tires Tires other than tho...

Page 87: ...l Type ATF DEXRON 3 Capacity 16 9 Quart 16 L CVT Oil Type CVT Case VALVOLINE INVARITORC 205 Dropcase ATF DEXRON 3 Capacity 18 L 0 90 L Axles Differential Mobilube HD Front Axle Capacity 8 0 quart 7 5...

Page 88: ...216201ADA SJ643 TH SJ843 TH 88 Notes...

Page 89: ...1ADA 89 Section 8 Labels Figure 62 Label legend Safety Red indicates DANGER Safety Orange indicates WARNING Safety Yellow indicates CAUTION Safety Green indicates Emergency Lowering Safety Blue indica...

Page 90: ...Panel Turn Signals Switch if equipped Select to signal left Select to signal right Hazard Warning Light Switch if equipped Always wear seat belt Absolutely no riders This vehicle is equipped with a ba...

Page 91: ...ct to turn on high beam headlights and tail lights Select to turn on low beam headlights and tail lights Positive Air Shutoff Switch if equipped Select to trigger the positive air shutoff valve Steeri...

Page 92: ...Move joystick right or left to extend or retract the boom Press and hold middle button and move joystick forward to tilt attachment forward Press and hold middle button and move joystick rearward to...

Page 93: ...r the boom Move joystick right or left to extend or retract the boom Hold left switch up to tilt attachment forward Hold left switch down to tilt attachment backward Press and hold frame level enable...

Page 94: ...l Add to full 10 hrs or Daily 50 hrs or Weekly 2 Check engine coolant level Add as required 3 Check transmission oil level with engine running Add to full 4 Check air cleaner indicator Squeeze vaccuat...

Page 95: ...Side 1 3 4 5 6 2 Description Label Pictorial 1 Keep Chains Tight Ensure chains are tight 2 Extension Letters Boom extension labels A B C D 3 Grease Grease point 4 Rotation Angle Boom rotation angle la...

Page 96: ...torial 7 Model Number Product identifier 25 White 8 Warning Do Not Alter Do not alter or disable limit switches or other safety devices 9 Keep Clear Keep clear 10 Body Crushing Hazard Danger Body crus...

Page 97: ...ressure or foam filled tires Tire pressure will vary may not be as shown 13 Unpinned Attachment Unpinned attachment warning 14 Tie down Points Only use these points for tying down TM 15 Model Number P...

Page 98: ...Pictorial 1 No Smoking Do not smoke near this location 2 Grease Grease point 3 Towing Capacity Telehandler s maximum towing capacity tongue weight 10205 kg MAX 22500 lb MAX 2041 kg MAX 4500 lb MAX 4 W...

Page 99: ...arning Do Not Alter Do not alter or disable limit switches or other safety devices 2 Model Number Product identifier 25 White 3 Skyjack Logo Skyjack logo 51 White 4 Grease Grease point 5 Keep Chains T...

Page 100: ...r Keep clear 9 Body Crushing Hazard Danger Body crushing hazard 10 Wheel Specifications Refer to manual for wheel type offset pressure and torque 11 Tire Pressure or Foam Filled Tires Indicates rated...

Page 101: ...1ADA 101 Models SJ643 TH SJ843 TH Section 8 Labels Description Label Pictorial 13 Crushing Hazard Danger Crushing hazard 14 Warning No Step No step warning 15 Skyjack Logo Skyjack logo 17 White Right...

Page 102: ...c oil 17 Hydraulic Oil Level Indicates minimum maximum oil level 18 Caution Coolant Fill Point Refer to service manual for coolant fill instructions 19 Main Power Disconnect Switch For use during main...

Page 103: ...3 TH SJ843 TH Section 8 Labels California Proposition Description Label Pictorial 1 Warning California Proposition 65 Cancer and Reproductive Harm https www p65warnings ca gov Cancer and Reproductive...

Page 104: ...216201ADA SJ643 TH SJ843 TH 104 CVT Transmission If Equipped Description Label Pictorial 1 EcoShift Logo CVT Transmission identifier 25 1...

Page 105: ...smission If Equipped Description Label Pictorial 2 EcoShift Logo CVT Transmission identifier 17 3 CVT Transmission Oil Refill with transmission oil VALVOLINE INVARITORC 205 VALVOLINE INVARITORC 205 AT...

Page 106: ...response to customer demands Easily sourced flat glass panels with no custom curved profiles and a bolt on bolt off window retention system ensures minimal downtime and incurred costs for repairing da...

Page 107: ...Cancer and Reproductive Harm https www p65warnings ca gov WARNING...

Page 108: ...www skyjack com...

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